Submerged arc welding system with pressurized flux delivery and welding torch

ABSTRACT

A submerged arc welding system. In one embodiment, the submerged arc welding system includes a robot, a flux supply distal from the robot, and at least one wire supply distal from the robot. The system also includes a welding torch connected to the robot, a wire path connecting the wire supply to the welding torch, and a flux path connecting the flux supply to the welding torch. A flux delivery system is configured to move flux from the flux supply to the welding torch. At least one vent is disposed on the flux path adjacent the welding torch, to evacuate air from the flux path.

FIELD OF INVENTION

The present application relates to a submerged arc welding system. Moreparticularly, the present application relates to an automatic submergedarc welding system with a pressurized flux delivery system.

BACKGROUND

Submerged arc welding is a type of welding where the arc is completelysubmerged in a covering of granular fusible flux. The flux protects themolten weld puddle from atmospheric contamination. Submerged arc weldingsystems, like other types of welding systems, may include a weldingpower supply, a wire feed control and drive assembly and a weldingtorch. In addition, submerged arc welding systems also include a fluxsystem. The flux system holds and delivers the flux to the weld jointduring welding.

SUMMARY

A submerged arc welding system is provided herein. In one embodiment,the submerged arc welding system includes a robot, a flux supply distalfrom the robot, and at least one wire supply distal from the robot. Thesystem also includes a welding torch connected to the robot, a wire pathconnecting the wire supply to the welding torch, and a flux pathconnecting the flux supply to the welding torch. A flux delivery systemis configured to move flux from the flux supply to the welding torch. Atleast one vent is disposed on the flux path adjacent the welding torch,to evacuate air from the flux path.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying drawings, structures are illustrated that, togetherwith the detailed description provided below, describe exemplaryembodiments of the claimed invention.

In the drawings and description that follows, like elements areidentified with the same reference numerals. The drawings are not toscale and the proportion of certain elements may be exaggerated for thepurpose of illustration.

FIG. 1 is a perspective view of one embodiment of a submerged arcwelding system attached to a robot;

FIG. 2 is a side view of one embodiment of a welding torch of thesubmerged arc welding system shown in FIG. 1;

FIG. 3 is a partial cross-section of one embodiment of a vent chamber ofa flux muffler for a welding torch of the submerged arc welding system;

FIG. 4 is a partial cross-section of one embodiment of a valve for awelding torch of the submerged arc welding system;

FIG. 5 is a side view of an alternative embodiment of a welding torch ofthe submerged arc welding system;

FIG. 6 is a partial cross-section of an alternative embodiment of a ventchamber of a flux muffler for a welding torch of the submerged arcwelding system; and

FIG. 7 is a partial cross-section of another alternative embodiment of avent chamber of a flux muffler for a welding torch of the submerged arcwelding system.

DETAILED DESCRIPTION

FIG. 1 is a perspective view of a submerged arc welding system 100 usedwith a robot R. In the illustrated embodiment, the robot R has a base B,a first arm A1, and a second arm A2. The first arm A1 is rotatablyconnected to the base B and is configured to rotate about a first axisX1 and a second axis X2. The second arm A2 is rotatably connected to thefirst arm A1 and is configured to rotate about a third axis X3 and afourth axis X4. In the illustrated embodiment, the robot R furtherincludes a torch mounting bracket M, connected to the second arm A2,that articulates about a fifth axis X5 and sixth axis X6. In one knownembodiment, the robot R is the ARC MATE 120iBe manufactured by FANUCROBOTICS. However, it should be understood that the illustrated robot Ris merely exemplary, and that the submerged arc welding system 100 maybe employed with any robot or robotic arm.

In the illustrated embodiment, the submerged arc welding system 100includes a welding torch 105 comprising a power block 110, a weldingtorch cable 115, and a nozzle 120. The welding torch cable 115 mayinclude an optional liner. In an alternative embodiment (not shown), thewelding torch includes a first power block, a second power block, and awire conduit and welding cables configured to handle required amperageconnected to the second power block. In one known embodiment, thewelding torch 105 weighs less than 20 kilograms. The welding torch 105is connected to the second arm A2 of the robot R by the torch mountingbracket M. In an alternative embodiment, the welding torch 105 isdirectly connected to the second arm A2.

A wire supply 125 supplies welding wire 130 to a wire motor 135, whichfeeds the welding wire 130 through the welding torch cable 115 of thewelding torch 105 and subsequently through the nozzle 120. In otherwords, the wire motor 135 moves the welding wire 130 from the wiresupply 125 along a wire path though the nozzle 120 of the welding torch105, wherein the wire path includes the wire motor 135 and the weldingtorch cable 115. The wire supply 125 is shown as a single spool ofwelding wire, but it should be understood that the wire supply 125 mayinclude two or more wire supplies, such as a first spool of welding wireand a second spool of welding wire. Where two or more wire supplies areemployed, a corresponding number of wire motors and welding torch cablesare employed. In other alternative embodiments (not shown), the wiresupply 125 may take the form of a reel, spool, drum, or box container.

In the illustrated embodiment, the wire supply 125 is not directlymounted to the robot R. Instead, the wire supply 125 is located distalfrom the robot R. The wire supply 125 may be located any distance fromthe robot R, such that it may be placed in a position suitable for aparticular environment. In most known welding environments, the wiresupply 125 will be located between about 1 meter to about 50 meters fromthe robot R.

The wire motor 135 is shown mounted to the first arm A1 of the robot R,behind the third and fourth axes. In alternative embodiments (notshown), the wire motor 135 may be mounted to the second arm A2 of therobot R, or placed in a location not connected to the robot R.

Additionally, the submerged arc welding system 100 includes a fluxsupply 140 that supplies flux through a flux line 145 to the weldingtorch 105. The flux includes granular fusible flux particles. The fluxparticles may include lime, silica, manganese oxide, calcium fluoride,or a combination thereof. The flux may also include flux fines (i.e.,small particles) and dust of the same or similar composition as the fluxparticles.

In one embodiment, the flux supply 140 includes a vacuum unit (notshown) having a hose extending adjacent the nozzle 120. The hose andvacuum unit are configured to use suction to collect flux particles thatpass through the nozzle 120 and remain on a surface.

In one embodiment, the flux supply 140 includes a pressurized fluxdelivery system that employs pressurized air to push or otherwise moveflux through the flux line 145, wherein the flux line 145 is directlyconnected to the welding torch 105. The flux supply 140 is shown as afeed tank, such as a pressurized feed tank. There is no interveninggravity hopper disposed between the flux supply 140 and the weldingtorch 105. In other words, the pressurized flux delivery system movesthe flux along a flux path from the flux supply 140 to the nozzle 120 ofthe welding torch 105, wherein the flux path does not include a gravityhopper.

The flux supply 140 is not directly mounted to the robot R. Instead, theflux supply 140 is located distal from the robot R. The flux supply 140may be located any distance from the robot R, such that it may be placedin a position suitable for a particular environment. In most knownwelding environments, the flux supply 140 will be located between about1 meter to about 20 meters from the robot R.

The submerged arc welding system 100 may also include a flux recyclingsystem (not shown) for recycling flux that is discharged through thenozzle 120. The flux recycling system may include one or more vacuumtubes that lead back to the flux supply 140 or to the flux line 145,thereby allowing discharged flux to be reused.

Additional details of the welding torch 105 and other components of thesubmerged arc welding system 100 can be seen in FIGS. 2-4. FIG. 2illustrates a side view of one embodiment of the welding torch 105. Thewelding torch 105 includes a flux muffler 150 disposed along the fluxpath and connected to the flux line 145. In the illustrated embodiment,the flux muffler 150 is adjacent to and connected with the welding torch105. In an alternative embodiment, the flux muffler 150 is integral withthe welding torch 105. In another alternative embodiment, the fluxmuffler 150 is spaced from the welding torch.

FIG. 3 illustrates a partial cross-section of the flux muffler 150. Theflux muffler 150 includes a vent chamber 155 inside a casing 160. Thevent chamber 155 has at least one vent 165 configured to removepressurized air from the flux path. In the illustrated embodiment, thevent chamber 155 is a tubular conduit having an input 170, an output175, and a plurality of elongated vents 165. In an alternativeembodiment, the vent chamber may have a square, rectangular, or othergeometric cross-section.

In the illustrated embodiment, the input 170 of the vent chamber 155 issmooth and has an outer diameter smaller than the inner diameter of theflux line 145, such that the input 170 may be inserted into the fluxline 145. The flux line 145 may have elastic properties to maintain aconnection with the vent chamber 155. In an alternative embodiment (notshown), the flux line 145 may be clamped onto the input 170 of the ventchamber 155. In other alternative embodiments, the input 170 of the ventchamber 155 may be threaded, or may have a snap-fit or otherconfiguration to be connected to the flux line 145.

In the illustrated embodiment, the output 175 of the vent chamber 155 isa threaded end, configured to be connected to a lower portion of theflux line 145. In alternative embodiments (not shown), the output 175 ofthe vent chamber 155 may be a smooth end, a snap-fit connector, or otherknown connector.

The vents 165 of the vent chamber 155 may be dimensioned to allow air topass through without allowing flux particles to pass through. In theillustrated embodiment, the casing 160 surrounds the vent chamber 155and is configured to capture any flux fines, dust, or other fluxparticles that pass through the vents 165 of the vent chamber 155. Thecasing 160 is open at the top to allow air to escape to the environmentand includes a filter F to capture flux fines and dust, preventing themfrom passing through the open top. Exemplary filters include steel wool,or other fibrous materials that will allow air movement but restrictsthe flux fines. In the illustrated embodiment, the filter F is onlylocated in an upper portion of the casing 160. In an alternativeembodiment (not shown), the filter F extends to the bottom of the casing160. In another alternative embodiment (not shown), the casing 160 doesnot include a filter. In yet another alternative embodiment (not shown),the casing 160 is closed at the top.

As shown in both FIGS. 2 and 3, the casing 160 is connected to asecondary flux line 180 that forms a path for the escaped flux fines,dust, and other flux particles. This path may be referred to as a fluxfines path, a flux return path, or a flux recycling path.

In the illustrated embodiment, the secondary flux line 180 isreconnected to the flux line 145 below the flux muffler 150 and abovethe nozzle 120. In this manner, the escaped flux fines, dust, and otherflux particles are recycled and rejoin the other flux particles. Thisprocess may be referred to as recycling, even though it occurs beforethe flux passes through the nozzle 120. The flux line 145 is connectedto the nozzle 120 such that the flux and the recycled flux fines, dust,and other flux particles travel through the flux line 145 and passthrough the nozzle 120. In one embodiment (not shown), the nozzle alsoincludes vent to evacuate remaining air to the environment.

With continued reference to FIG. 2, a flux valve 185 is located alongthe flux line 145, and is configured to control the release of flux fromthe flux path to the nozzle 120 of the welding torch 105. In theillustrated embodiment, the flux valve 185 is directly below the fluxmuffler 150 and spaced from the nozzle 120 of the welding torch 105. Inan alternative embodiment, the flux valve may be adjacent the nozzle 120of the welding torch 105.

In one known embodiment, the flux valve 185 is a SPARTAN SCIENTIFICSERIES APV-23 valve. In alternative embodiments, the flux valve 185 is apinch, gate, or a butterfly style valves. In one embodiment, the fluxvalve 185 is normally biased in a closed position to prevent flux fromaccidentally being discharged through the nozzle 120.

FIG. 4 illustrates a partial cross-section of the flux valve 185. Theflux valve 185 is substantially cylindrical and includes a piston 190configured to extend into and seal a tube 195. The piston 190 is furtherconfigured to be retracted from the tube 195, thereby creating anopening along flux to pass through. The flux valve 185 may include aspring extended pneumatic operator to control extension or retraction ofthe piston 190.

FIG. 5 illustrates a side view of an alternative embodiment of a weldingtorch 200 that is substantially the same as the welding torch 105 exceptfor the differences described herein. The alternative welding torch 200includes an alternative flux muffler 205.

A partial cross-section of the alternative flux muffler 205 isillustrated in FIG. 6. The flux muffler 205 is substantially the same asthe flux muffler 150, except for the differences described herein. Thealternative flux muffler 205 includes a vent chamber 210 in a casing215. However, the casing 215 is not connected to secondary flux lineleading towards the nozzle of the welding torch. Instead, the casing 215is connected to a vacuum tube 220 that leads away from the nozzle andforms a path for the escaped flux fines, dust, and other flux particles.

In one embodiment, the vacuum tube 220 is connected to the flux supply.In an alternative embodiment, the vacuum tube 220 is connected to theflux line. In both embodiments, escaped flux fines, dust, and other fluxparticles are reused. This process may be described as recycling, eventhough it occurs before the escaped flux fines, dust, and other fluxparticles are discharged through the nozzle.

In the illustrated embodiment, the casing 215 is open at the top andincludes an internal filter F to capture flux fines and dust, preventingthem from passing through the vents. Exemplary filters include steelwool, or other fibrous materials that will allow air movement butrestricts the flux fines. In the illustrated embodiment, the filter F isonly located in an upper portion of the casing 215. In an alternativeembodiment (not shown), the filter F extends to the bottom of the casing215. In another alternative embodiment (not shown), the casing 215 doesnot include a filter. In yet another alternative embodiment (not shown),the casing 215 is closed at the top.

FIG. 7 illustrates another alternative embodiment of a flux muffler 300.In this embodiment, the flux muffler 300 is substantially the same asthe flux muffler 150 and the alternative flux muffler 205, except theflux muffler 300 includes a casing 305 having a plurality of vents 310.The flux muffler 300 does not include a secondary flux line or a vacuumtube. Instead pressurized air is simply evacuated through the vents tothe environment.

In the illustrated embodiment, a vent chamber 315 inside the casing alsohas a plurality of vents (not shown). In one embodiment, the fluxmuffler 300 further includes an internal filter disposed between thevent chamber 315 and the casing 305 to capture flux fines and dust,preventing them from passing into the environment. Exemplary filtersinclude steel wool, or other fibrous materials that will allow airmovement but restricts the flux fines.

To the extent that the term “includes” or “including” is used in thespecification or the claims, it is intended to be inclusive in a mannersimilar to the term “comprising” as that term is interpreted whenemployed as a transitional word in a claim. Furthermore, to the extentthat the term “or” is employed (e.g., A or B) it is intended to mean “Aor B or both.” When the applicants intend to indicate “only A or B butnot both” then the term “only A or B but not both” will be employed.Thus, use of the term “or” herein is the inclusive, and not theexclusive use. See, Bryan A. Garner, A Dictionary of Modern Legal Usage624 (2d. Ed. 1995). Also, to the extent that the terms “in” or “into”are used in the specification or the claims, it is intended toadditionally mean “on” or “onto.” Furthermore, to the extent the term“connect” is used in the specification or claims, it is intended to meannot only “directly connected to,” but also “indirectly connected to”such as connected through another component or components.

While the present application has been illustrated by the description ofembodiments thereof, and while the embodiments have been described inconsiderable detail, it is not the intention of the applicants torestrict or in any way limit the scope of the appended claims to suchdetail. Additional advantages and modifications will readily appear tothose skilled in the art. Therefore, the application, in its broaderaspects, is not limited to the specific details, the representativeapparatus and method, and illustrative examples shown and described.Accordingly, departures may be made from such details without departingfrom the spirit or scope of the applicant's general inventive concept.

What is claimed is:
 1. A submerged arc welding system for use with arobot having at least a base, a first arm rotatably connected to thebase, and a second arm rotatably connected to the first arm, thesubmerged arc welding system comprising: a welding torch having anozzle, wherein the welding torch is connected to the second arm of therobot; at least one wire supply configured to be located distal from therobot; a wire path connecting the at least one wire supply to the nozzleof the welding torch; a flux supply including a pressurized fluxdelivery system and a vacuum unit, the pressurized flux delivery systemconfigured to move flux from the flux supply, along the flux path, tothe welding torch, and the flux supply configured to be located distalfrom the robot; a flux path connecting the flux supply to the nozzle ofthe welding torch, wherein the flux path does not include a gravityhopper; a flux muffler disposed along the flux path, connected to thewelding torch, the flux muffler comprising a casing, and having aplurality of vents in a vent chamber located within the casing; arecycle line connected to the casing of the flux muffler to transportfrom the flux muffler escaped flux fines that pass through the vents;and a flux valve disposed along the flux path.
 2. The submerged arcwelding system of claim 1, further comprising a wire motor configured tomove wire from the at least one wire supply along the wire path to thewelding torch.
 3. The submerged arc welding system of claim 2, whereinthe wire motor is connected to the first arm of the robot.
 4. Thesubmerged arc welding system of claim 1, wherein the pressurized fluxdelivery system is configured to be located distal from the robot. 5.The submerged arc welding system of claim 1, wherein the recycle lineconnects the flux muffler to the flux path at a location adjacent thenozzle of the welding torch.
 6. The submerged arc welding system ofclaim 1, wherein the recycle line connects the flux muffler to the fluxpath at a location distal from the welding torch.
 7. The submerged arcwelding system of claim 1, wherein the flux valve is adjacent the nozzleof the welding torch.
 8. The submerged arc welding system of claim 1,wherein the flux valve is biased in a closed position.
 9. The submergedarc welding system of claim 1, wherein the flux valve includes a pistonand cylinder.
 10. A submerged arc welding system comprising: a robot; aflux supply distal from the robot; at least one wire supply distal fromthe robot; a welding torch connected to the robot; a wire pathconnecting the at least one wire supply to the welding torch; a fluxpath connecting the flux supply to the welding torch; a flux deliverysystem configured to move flux from the flux supply to the weldingtorch; a flux muffler disposed along the flux path, the flux mufflercomprising a casing, and having a plurality of vents in a vent chamberlocated within the casing; and a recycle line connected to the casing ofthe flux muffler to transport from the flux muffler escaped flux finesthat pass through the vents.
 11. The submerged arc welding system ofclaim 10, wherein the welding torch includes a nozzle and a flux valveadjacent to the nozzle, the flux valve being biased in a closedposition.
 12. The submerged arc welding system of claim 10, wherein theat least one wire supply includes at least a first wire supply and asecond wire supply.
 13. The submerged arc welding system of claim 10,further comprising a wire motor mounted to the robot.
 14. An automaticsubmerged arc welding system comprising: a welding torch having anozzle; means for transporting flux from the flux supply directly to thewelding torch; a flux muffler disposed along the means for transportingflux, the flux muffler comprising casing, and having a plurality ofvents in a vent chamber located within the casing; a recycle lineconnected to the casing of the flux muffler to transport from the fluxmuffler escaped flux fines that pass through the vents; means forcontrolling release of flux to the nozzle of the welding torch; andmeans for transporting wire from the wire supply to the welding torch.15. The automatic submerged arc welding system of claim 14, furthercomprising a robotic arm.
 16. The automatic submerged arc welding systemof claim 15, wherein the flux supply includes a vacuum unit and islocated distal from the robotic arm, and wherein the wire supply islocated distal from the robotic arm.
 17. The automatic submerged arcwelding system of claim 14, wherein the recycle line is configured torecycle the flux fines, which do not pass through the nozzle of thewelding torch.
 18. A welding torch comprising: a nozzle; a wire pathconnected to the nozzle; a flux path connected to the nozzle; a fluxmuffler disposed along the flux path, the flux muffler comprising acasing, and having a plurality of vents in a vent chamber located withinthe casing; a recycle line connected to the casing of the flux mufflerto transport from the flux muffler escaped flux fines that pass throughthe vents; and a flux valve disposed along the flux path.
 19. Thewelding torch of claim 18, wherein the flux valve includes a pistonbiased in a closed position.
 20. The submerged arc welding system ofclaim 1, wherein the vent chamber comprises a conduit located within thecasing of the flux muffler, and the flux muffler is disposed along theflux path above the nozzle of the welding torch.
 21. The submerged arcwelding system of claim 20, wherein the flux valve is disposed along theflux path between the flux muffler and the nozzle of the welding torch.22. The submerged arc welding system of claim 11, wherein the ventchamber comprises a conduit located within the casing of the fluxmuffler, and the flux muffler is disposed along the flux path above thenozzle of the welding torch.
 23. The submerged arc welding system ofclaim 22, wherein the flux valve is disposed along the flux path betweenthe flux muffler and the nozzle of the welding torch.
 24. The automaticsubmerged arc welding system of claim 14, wherein the vent chambercomprises a conduit located within the casing of the flux muffler, andthe flux muffler is disposed along the means for transporting flux abovethe nozzle of the welding torch.
 25. The submerged arc welding system ofclaim 24, wherein the flux valve is disposed along the means fortransporting flux between the flux muffler and the nozzle of the weldingtorch.
 26. The welding torch of claim 18, wherein the vent chambercomprises a conduit located within the casing of the flux muffler, theflux muffler is disposed along the flux path above the nozzle, and theflux valve is disposed along the flux path between the flux muffler andthe nozzle.